Method of producing heat-resisting bodies.



P. R. HERSHMAN METHOD OF PRODUCING HEAT RESISTING BODIES.

I APPLiCATlON FILED OCT. 12, 1914. 1,135,182.

Patented Api'. 13, 1915.

, body filings, grindings,

; TED STAES PAUL Burn H BSHMAN, 0E CHICAGO, rumors, assrsnon ro ARMOUR FERTILIZER worms, or CHICAGO, ILLINOIS, A CORPORATION or NEW JERSEY.

MErHon' or PRODUCING HEAT-BESISTING BODIES.

Specification of Letters Patent.

Patented Apr. 13, 1915.

Application tiled October 12, I914. Serial Il'o. s dfl fiil the present invention is the production of bodies of heat-resisting material, preferably solid, massive bodies, capable of employment as furnace linings and in other relations where heat-resisting materials are necessary, and able to withstand the highest temperatures obtainable in electric or similar furnaces without being injured, cracked or caused to chip of]? by the heat at the high temperatures employed.

Another salient feature and purpose of the invention resides in the manufacture of such bodies or furnace linings of this character from aluminum waste products, or other suitable materials easily and cheaply procurable, whereby their production may be efi'ected economically.

In order that those skilled in this art may have a full and complete understanding of the invention, I have illustrated in the accompanying drawing, forming a part of this specification, the various steps employed in carrying out the improved process, and in th s drawing, Figure 1 illustrates the mol ing of the plastic mass into suitable shape in one of the furnace parts or halves; Fig. 2 shows the initial heating of the mass at a relatively low temperature; Fig. 3 illustrates the two parts of the furnace lining assembled and subjected to further heating at a low temperature; Fig. 4 shows the further heating of the two parts of the lining at a higher temperature by the electric arc in the presence of a gas incapable of combining with carbon at the temperature employed; and Fig. 5 illustrates the completed parts of the furnace lining. In all of these figures of the drawing the furnace is illustrated in section.

This improved and novel method consists, in its preferred form, in mixing a heated of relatively cheap, aluminum parcommercial by-products, shavings, &c., which may incidentally contain a certain iron, and silicon, with a ticles, such as the however, amount of copper,

sufficient quantity of heated, melted, heavy tar, to form a thick, plastic mass. This body of aluminum particles is initially or preliminarily heated, so that when mixed with the melted tar it will have no chilling action on the latter, the result being a more uniform plastic mass. The finer or smaller the aluminum particles are, the better, but in ordinary practice particles approximating 1/32 inch, l/Gi inch, or less, in diameter, are suitable for the purpose.

The tar is used both as a binder for the aluminum particles and also to cause the formation of carhids. Tar is employed in the preferred way of carrying out the process because it is relatively cheap, and the percentage used depends somewhat upon the sizes of the aluminum particles. An average amount of the tar used would be approximately 25% to 50% of the Weight of the aluminum, which mixture results in a semi-paste. Various other carbonaceous materials might be used in place of the tar, such, for example, as glue, sugar, molasses, and the like. If desired, approximately one to two per cent. of magnesium dust, based on the weight of the aluminum used, may be added by first intimately mixing it with the aluminum particles, the function of the magnesium dust being to render the lining harder; but it is to be understood that it is not necessarily an essential ingredient of the mixture. This mass is molded into shape preferably by using each of the-two furnace halves as molds, and in conjunction with suitably shaped cores to provide the necessary cavities in the finished lining, and-the mass is reinforced and maintained-in position by means of small aluminum wires, rods or bolts, embedded in the mass and suitably fastened to the mold or furnace casing. These aluminum wires or rods act to hold the mass of material in better shape while drying and hardening, and are burned or consumed as the temperature is raised in wires or rods, magnesium or similar wires may be employed. These wires 3.16-O1'dl narily held in vertical position by suitable fastenin means, such as scre'w'threads or nuts, an

they may be from one thirty-sec .1.

Ill

0nd to a quarter of an inch in diameter, and about one or two feet in length, but it is to be understood that their dimensions may be varied within wide l fits.

In shaping or moh'iing the mass in each of the furnace halves, it is tamped, compacted or condensed as solidly as possible while still hot. Each mass or body, with the embedded rods, is dried in the air for approximately half a day, and is preferably subjected to the 'action.of a relatively low temperature by means of a charcoal fire placed in the cavity from which the core has been removed, the charcoal being covered over sutficiently to exclude an excess of air. After the two blocks have become sutliciently hardened by this action of the heat, the two parts of the furnace are assembled, so that the two masses of the material are in juxtaposition, with the usual cavity between them, the rods 01' wires assisting in holding the lining parts in place. A charcoal fire isthen built in this cavity, which subjects the blocks of inaterial to a moderate temperature of approximately 800 Centigrade for about one or two days. Then the charcoal tire is removed and the lining is electrically heated, by the electric are or otherwise, to form one thousand to two thousand degrees centigrade in a current of gas incapable of combining with the carbon at'the temperature employed, such for instance as carbon monoxid, hydrogen, &c. During the application of this higher temperature, the aluminum supporting or reinforcing rods are consumed and disappear, and the aluminum particles combine or react with the carbonaceous matter, producing a furnace lining with remarkable heat-resisting qualities, experience showing that such linings will resist or stand temperatures above 2000 ccntigrade withoutinjury. v

Tn the drawing, I have illustrated, in Fig. 1, one of the furnace halves used as a mold and containing the mixture 10, which has embedded therein its reinforcing and'supporting aluminum rods, pins or bolts 11, 11. This mass of material brought to proper shape by the use of a wooden core 12. As is clearly illustrated, the reinforcing rods are fastened by means of nuts 13 to the shell 1- of the furna e, it should be understood that each half of the furnace is supplied with such a mass of the plastic mixture.

After this mass has been properly condensed and compacted, and brought to the desired shapein each half of the furnace (only one of which halves is illustrated in Fig. 1), the core is removed and the mass allowed to dry in the air for any suitable lenglh of time. its cavitjv is then supplied with a charcoal lire, over which a cover 15 is placed, and the mass of material is thus heated at a moderate temperature for about half a day.

This part of the process is illustrated in Fig. Then the two parts of the lining are sutlieiently hard so that the two parts of the furnace may be assembled in their usual rela tion, with the two blocks of material one above the other and their cavities registering, as

shown in Fig. 3, the masses of material be ing held in place by the rods. Then a charcoal fire is built in this cavity, and the blocks of material are subjected to a temperature of approximately 800 centigrade for one or two days, as isshown in Fig. 3.

Then the charcoal fire is removed and the electric terminals 16 and 17 inserted, as

shown in Fig. 4, after which the two parts of the lining are subjected to the heat of an electric are between these terminals, which raises the temperature to approximately 1000 to 2000 centigrade, and at the same time a currentof a gas incapable of combining with the carbon at the temperature employed passes through the furnace. A gas suitable for this purpose may be carbonv monoxid, hydrogen, &'c. At this high temperature the aluminum rods or bolts disappear by reason of their consumption, and

the lining parts harden and become refractor and heat-resisting to such a degree that they will withstand excessively high tem perritures. The finished lining is illustrated in lig, 5.

While I have herein set'forth in detail the ingredients employed, the percentages used and the temperatures suitable for the purpose, it-is to be understood that these 'may be modified materially without depart inr; from the substance of the invention, and

that materials other than aluminumsinay be used as the main ingredient of the n iixture.

The scope of the invention is defined by tlxe appended claims,- and I'm-do not wish therefore to be limited by the above descript' on except as such claims require.-

1 claim:

1. The method consisting of mixing with carbonaceous material a body of particles. capable of reacting with carbon, and heating such mixture at a suflicient temperature and for a sufficient length of time to effect such reaction without liquefaction, producing a solid mass of heat resisting material suitable for use as a furnace lining, substantially as described.

2. The method consisting of forminga plastic mass by mixing a carbonaceous binder with a body of particles capable of reacting with carbon, and heating such mass to elfectthe reaction without liquefaction, producing a solid body of heat resisting material suitable for use as a furnace lining, substantially as described.

3. The method of producing a solid mass of heat-resisting material which cons sts in mixing a body of aluminum particles :with

ture to effect the reaction between the ingredients, substantially as described.

4:. The method of producing a solid body of heat-resisting material which consists in forming a plastic mass by mixing a body of aluminum particles with a carbonaceous binder, and heating the mass at a sufiicient temperature and for a sufficient length of time to effect the reaction between the ingredients, substantially as described.

5. The method consisting of forming a plastic mass by mixing with a carbonaceous binder a body of particles capable of reacting with carbon, and heating the mass first at a moderate temperature and then at a higher temperature to effect the reaction between the ingredients without liquefaction, producing a solid mass of heat resisting material suitable for use as a furnace lining, substantially as described.

6. The method consisting of forming a plastic mass by mixing with a carbonaceous binder a body of particles capable of reacting with carbon heating the mass at a moderate temperature and then at a higher temperature without liquefaction in the pres ence of a gas incapable of combining with carbon at the higher temperature employed, producing a solid mass of heat resisting material suitable for use as a furnace lining, substantially as described. I

7. The method consisting of forming a plastic mass by mixing a body of aluminum particles with a carbonaceous binder, heating the mass first at a moderate temperature and then at a higher temperature without liquefaction in the presence of a gas incapable of combining with carbon at the' higher temperature employed, producing a heat resisting material suitable for use as a furnace lining, substantially as described.

8. The method consisting of forming a plastic mass by mixing with a heated caronaceous binder a heated body of particles capable of reacting with carbon, heating such mass first at a moderate temperature and then at a higher temperature without liquefaction of the ingredients, producing a solid mass of heat resisting material suitable for use as a furnace lining, substantially as described.

9. The method of producing a solid mass of heat-resisting material consisting forming a plastic mass by mixing a heated body of aluminum particles with a heated carbonaceous binder, heating the mass first at a moderate temperature, and then at a higher temperature in the presence of a gas incapable of combining with carbon at the temperatures employed, substantially as described.

10. The method of producing a solid mass of heat-resisting material consisting in mixin a heated body of aluminum particles with melted tar to form a plastic mass, and

heating the mass to effect the reaction between the ingredients, substantially as described.

11. The method of producing a solid mass of heat-resisting material consisting in mixing a heated body of aluminum particles with melted tar to form a plastic mass, heating the mass at a moderate temperature, and then at a higher temperature to eifect the reaction between the ingredients, substantially as described.

12. The method of producing a solid mass of heat-resisting material consisting in mixing a heated body of aluminum particles with melted tar to form a plastic mass, heat ing the mass at a moderate temperature, and then at a higher temperaturein the presence of a gas incapable of combining with carbon at the temperatures employed, substantially as described.

13. The method of producing a solid mass of heat-resisting material consisting in mixing a heated. body of aluminum particles with melted tar to form a plastic mass, heating the mass at a moderate temperature, and then heating the mass in situ as a furnace lining at a higher temperature, substantially as described.

14:. The method of producing a solid mass of heat-resisting material which consists in forming a plastic mass by mixing with a carbonaceous binder a body of particles capable of reacting with carbon, heating such mass at a moderate temperature by means of a charcoal fire, and subsequently heating the mass at a higher temperature in situ as a furnace lining, substantially as described.

15. The method of producing a body of heat-resisting material consisting in mixing with carbonaceous material a body of particles capable of reacting with carbon, embedding reinforcing means in such mixture, and heating such mixture at a sufficient tem peratu-re and for sufficient length of time to effect the reaction between the ingredients and cause the consumption of the reinforcing means, substantially as described.

16. The method of producing a solid. mass of heat-resisting material which consists in forming a plastic mass by mixing with a carbonaceous binder a body of particles capable of reacting with carbon and embedding reinforcing means in the mixture, and heating such mass at a sufiicient temper ature and for a sufficient length of time to effect the reaction between the ingredients and cause the consumption of the reinfore ing means, substantially as described.

17. The method of producing a solid mass of heat-resisting material which consists in mixing a body of aluminum particles with -mass, and heating the mass at a sufiicient temperature and for a suflicient'length of time to effect the reaction between the ingredients and cause the consumption of the reinforcing means, substantially as described.

18. The method of producing a solid mass of heat-resisting material which consists in mixing a body of aluminum particles with a carbonaceous binder to form a plastic mass, embedding aluminum reinforcing rods in such mass, and heating the mass at a sufficient temperature and for a sufficient length of time to effect the reaction between the ingredients and cause the consumption of the reinforcing rods, substantially as described.

19. The method of producing a solid mass of heat-resisting material consisting in mixing a heated body of aluminum particles with melted tar to form a plastic mass, embedding reinforcing aluminum rods in said mass, heating the mass at a moderate temperature, and then at a higher temperature in the presence of a gas incapable of combining with carbon at the temperatures employed, whereby to effect the reaction between the ingredients and cause the consumptlon of the reinforcing rods, substanin the presence of a gas inc-pable of combining with carbon at the temperatures employed, whereby to effect the reaction be-.

tween the ingredients and cause the con-- 1,135,182 if a *i sumption of the reinforcing rods, substan described. PAUL RALPH HERSHMAN. lVitnesses:

O. LAAG, Jr.,

C. F. HAGEDORN.

tially as 

